Stretchable Donor Plate for Precise Uneven-Surface Deposition
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing deposition methods struggle to accurately deposit donor materials on uneven surfaces, such as those with multiple layers or components with elevated terminals, due to the limitations of flat-surface deposition techniques.
Innovation Solution
A method involving a stretchable layer with patterned recessed areas filled with donor material, pressurized to conform to the target surface, and irradiated with photon radiation to transfer the material accurately, using a deposition device with controlled pressure and photon radiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a flat surface deposition method is used, then the deposition process is simple, but the manufacturing precision deteriorates when depositing on uneven surfaces
Solution Approach 1:
The plate is designed with a flexible or stretchable layer that can dynamically adapt its shape to match the target surface geometry. This dynamic capability allows the plate to conform to uneven surfaces during deposition, maintaining manufacturing precision without complicating the overall process
Solution Approach 2:
The physical state or mechanical properties of the plate's flexible layer are changed to enable it to deform and conform to the target surface. By controlling parameters such as elasticity, viscosity, or mechanical compliance, the plate achieves precise material transfer on uneven surfaces while maintaining process simplicity
2Manufacturing precision
If a flexible plate is used to conform to uneven surfaces, then the manufacturing precision improves, but the device complexity increases
Solution Approach 1:
A flexible layer or thin film is integrated into the plate structure to enable conformance to uneven surfaces. This flexible component allows the plate to adapt to complex geometries while keeping the overall device structure relatively simple and manageable
Solution Approach 2:
The flexible plate design serves multiple functions: it acts as both the deposition carrier and the conforming element. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity while achieving high manufacturing precision on uneven surfaces
3Manufacturing precision
If the plate is pressurized to conform to the target surface, then the manufacturing precision improves, but the force required increases
Solution Approach 1:
The mechanical properties of the flexible layer are optimized to achieve conformance with minimal applied pressure. By adjusting parameters such as elasticity modulus, viscosity, or layer thickness, the system achieves the necessary alignment accuracy while minimizing the force required
Solution Approach 2:
The flexible layer dynamically adjusts its deformation state in response to applied pressure, achieving optimal conformance with the target surface. This dynamic response allows for precise alignment with minimal force, as the layer adapts to surface variations rather than requiring high static pressure
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables precise deposition of donor materials on uneven surfaces by conforming the stretchable layer to the target surface, ensuring accurate transfer and alignment of materials like electrical connections.
Implementation Method 1
providing a relatively high pressure in an interior of the enclosure as compared to a pressure in an exterior of the enclosure. As a result of providing the relatively high pressure, a volume of the interior is increased so that the patterned surface of the stretchable layer is pressed against the target surface
Implementation Method 2
the photon radiation has an intensity and a duration that causes a transfer of donor material from the one or more recessed areas to the target surface. The photon radiation is transmitted through the substrate and the stretchable layer to within the one or more recessed areas, where it induces a vapor pressure
Implementation Method 3
induces a vapor pressure at an interface of the donor material facing the flexible layer that results in an ejection of the donor material out of the one or more recessed areas towards the target surface
Data Source
AI summary
A method of depositing a donor material onto a target surface is provided herein, in which a first main side of a substrate is covered with a stretchable layer that is attaching thereto with a sealing around an enclosed area at the first main side, therewith defining an enclosure. The stretchable layer has an outer surface that faces away from the substrate, and that is patterned with one or more recessed areas filled with the donor material to be deposited. A relatively high pressure is provided in an interior of the enclosure so that its volume is increased and the patterned surface of the stretchable layer is pressed against the target surface. In that state of the stretchable layer the substrate is irradiated at a second main side opposite its first main side with photon radiation that has an intensity and a duration that causes a transfer of donor material from the one or more recessed areas to the target surface. Also a plate and a deposition device are provided.